Shafer SH-Series Poppet Block Owner's manual

Brand: Shafer

Model: SH-Series Poppet Block

Type: Owner's manual

Maintenance and Service Manual

0.125 PBC 110209

Nov. 2, 2009

1/8" POPPET BLOCK CONTROL

MAINTENANCE AND SERVICE MANUAL

USASI SCHEMATIC

Normally closed, double three-way

valve. Shown manually operated.

Maintenance and Service Manual

0.125 PBC 110209

November 4, 2009

1/8" Poppet Block Control

Page 2

POPPET BLOCK

GAS OR OIL FLOW

FIGURE 2A

INTRODUCTION

The poppet block is the heart of most Shafer

control systems. A double three-way, manual and

pilot actuated, control valve is designed to

provide selective directional operation of Shafer

actuators. The poppet block control may direct

power gas to a set of gas/hydraulic tanks

(generating hydraulic pressure for powering valve

actuators), or it may direct central hydraulic

system pressure directly into a valve actuator. It

is engineered to provide reliable and durable-

operation and toleration of contaminates in the

power source.

FIGURE 1

OPERATION

FIGURE 1 – NEUTRAL POSITION

Spring compression (1) and power gas force the

power poppets (2) on their respective seats and

simultaneously hold exhaust poppets (3) in the

open position via interconnecting poppet pins.

Tank porting is open to exhaust.

FIGURE 2A – PILOT ACTIVATION

Pilot pressure to the pilot piston (5) illustrates

force applied to the piston seating the exhaust

poppet and simultaneously unseating the power

poppet. Power gas is directed through tank port

“B”.

BASIC CONSTRUCTION

The poppet block consists of a double three-way

ported valve body containing two sets of

inexpensive, easily replaced nylon poppets to

provide tight sealing, poppet springs, push pins,

manual needle screw override assemblies and

pilot pistons for remote operation.

NOTE: Pilot pressure to the opposite pilot pisto

shown in Figure 2A will activate the

opposite set

of poppets and direct power gas to tank port “A”.

NOTE: Pilot pistons are equipped with an orifice

in order to vent the pilot pressure and allow the

control to neutralize after stroking an actuator.

Maintenance and Service Manual

0.125 PBC 110209

November 4, 2009

1/8" Poppet Block Control

POPPET BLOCK

GAS OR OIL FLOW

FIGURE 2 B

Page 3

FIGURE 3

FIGURE 2B – MANUAL ACTIVATION

Opening the Needle Screw Manual Override (6)

will admit power pressure to the pilot piston (5)

seating the exhaust poppet and simultaneously

unseat the power poppet. Power gas is directed

through the tank port “A”.

NOTE: Turn Needle Screw counter-clockwise to

open, clockwise to close.

CAUTION: Do Not over torque Needle Screws.

For positive shut-off, use a

conventional 3/8" open or box end

wrench.

FIGURE 3 – NEUTRALIZATION

Closing the Needle Screw Manual Override will

allow the compressed poppet spring and power

gas to reseat the power poppet and

simultaneously unseat the exhaust poppet.

Power gas pressure remaining in the

gas/hydraulic tank is now vented through port “B”

to the exhaust, thus neutralizing tank and

actuator pressures.

Maintenance and Service Manual

0.125 PBC 110209

November 4, 2009

1/8" Poppet Block Control

Page 4

BASIC CHECK-OUT

PROCEDURES

CHECK NO. 2

The following two checks can verify the proper

working functions of the Shafer Poppet Block/

Failure of either of these procedures may result in

operating problems with the valve actuator. This

description is for gas service, but the unit can

also be used in hydraulic service.

Open the Manual Needle Screw Manual Override

and stroke the actuator

partially open or closed.

NOTE: The Manual Needle Screw for open and

close are indicated on the attached tag.

After stroking the actuator partially open or

closed, close the Needle Screw thus exhausting

the gas/hydraulic tank.

CHECK NO. 1

After gas/hydraulic tank is completely exhausted,

check the exhaust port for any gas leakage.

There should be zero leakage throughout the

control syst

NOTE: The exhaust po

rt should be free of any

restrictions or piping size reductions less than

1/8, unless factory supplied. (Standard factory

suppled units will include a high pressure

Exhaust Muffler.)

In the neutralized position there should be zero

leakage fro

the exhaust port.

Power gas leakage is usually attributed to debris

lodged between the power poppet and seat.

BILL OF MATERIAL

FIGURE 4A

Maintenance and Service Manual

0.125 PBC 110209

November 4, 2009

1/8" Poppet Block Control

BILL OF MATERIAL

FIGURE 4B

ITM QTY. DESCRIPTON ITM QTY

1 1 1/8” POPPET BLOCK BODY

17 2 O-RING – PISTON

2 1 1/8” POPPET BLOCK END CAP

18 2 BACK-UP RING - PISTON

3 1 1/8” P. BLK. EXHAUST POPPET CAP

19 2 O-RING – SEAT INSERT

4 2 1/8” POPPET BLOCK SEAT INSERT

20 2 O-RING – SEAT INSERT

5 2 1/8” POPPET BLK NEEDLE SCREW

21 2 O-RING – NEEDLE SCREW

6 2 1/8” POPPET BLOCK PILOT PISTON

22 2 O-RING – BOTTOM CAP

7 4 1/8” POPPET BLOCK POPPET

23 2 O-RING – TOP CAP

8 2 1/8” POPPET PIN

9 2 1/8” POPPET BLK SPRING SPACER

25 2 O-RING – MANIFOLD

10 2 SPRING

26 2 FLUSH PLUG LEVEL SEAL

11 2 1/8” POPPET BLOCK HEX END

27 4 SOCKET HEAD CAP SCREW MTG.

12 2 SOCKET HEAD SET SCREW FLAT PT

13 4 SOCKET HEAD CAP SCREW - TOP

29 2 ORFICE PLUG

14 4 SOCKET HEAD CAP SCREW – BTM.

30 2 SOCKET SET SCREW HFDOG

15 2 SLOTTED HEAL WIPER

31 1 O-RING - UPPER CAP

Page 5

Maintenance and Service Manual

0.125 PBC 110209

November 4, 2009

1/8" Poppet Block Control

Page 6

DISASSEMBLY &

ASSEMBLY

PROCEDURE

DISASSEMBLY

WARNING: Isolate and disarm control. Turn off

power gas, bleed off gas volume in

power storage tank if so equipped,

open and close both Needle

Screws Item (5) to vent any

entrapped pressure.

NOTE: Before continuing assure the

availability of spare o-rings and poppets.

1. Remove four M8 x 50 mm Socket Head Cap

Screws Item (27) releasing the Poppet Block

Assembly from the actuator.

NOTE: Take caution with the two manifold O-

rings Item (25) located between the Poppet

Block and actuator.

2. Remove two 10-32 x 1/4" Socket Head Set

Screws Item (30) from Poppet Block Body

Item (1). Access to these Set Screws is

located on the sides of the body, Illustrated in

Figure 5.

NOTE: These two set screws are located

deep inside the body Item (1) and require a

long Allen Wrench to remove and reinstall.

3. Remo

ve four 10-32 x 1/4" Socket Head Set

Screws Item (30) located on the top of the

Poppet Block Assembly.

4. Remove one end Cap Item (2) and O-rings

Item (23).

5. Remove two Spring Spacers Item (9), Spring

Item (10), Two Poppets Item (7) & two Poppet

Pins Item (8).

6. Remove two 8-32 x 3/8" Socket Head Set

Screws Item (12) from the two Hex Ends Item

(11) located on the bottom of the assembly

and remove the two Hex Ends from the

Needle Screws Item (5).

7. Remove four 1/4"-20 x 1" Socket Head cap

Screws Item (14), one end Cap Item (3) and

two O-Rings Item (22).

NOTE: When removing the End Cap Screws

Item (3), the two Needle Screws Item (5) and

two Seat Inserts Item (4) can all be removed

as an assembly.

8. Unthread two Needle Screws Item (5) from

Seat Insert Item (4).

9. Remove two Pilot Pistons Item (6) and two

Poppets Item (7). Each Pilot Piston has a 10-

31 tapped hole in the bottom and can be

removed from the Body with one of the 10-31

x 5/8 Socket Head Cap Screws Item (13).

FIGURE 5

NOTE: Do not remove Pipe Plugs Items (29) and

(26) located on both sides of Body Item

(1). See

Figure 6.

Maintenance and Service Manual

0.125 PBC 110209

November 4, 2009

1/8" Poppet Block Control

13 4 pcs.

23 2 pcs.

9 2 pcs.

10 2 pcs.

7 2 pcs.

8 2 pcs.

Page 7

27 4 pcs.

7 2 pcs.

18 2 pcs.

17 2 pcs.

6 2 pcs.

19 2 pcs.

20 2 pcs.

4 2 pcs.

21 2 pcs.

5 2 pcs.

22 2 pcs.

15 2 pcs.

3 2 pcs.

14 4 pcs.

12 2 pcs.

11 2 pcs.

25 2 pcs.

29 2 pcs.

26 2 pcs.

30 2 pcs.

FIGURE 6

ASSEMBLY

1. Replace all O-rings, Back-up Rings, Wipers,

Poppets and Springs listed in the Seal Kit

Table Figure 7.

2. During Reassembly refer Figure 5 to ensure

two Needle Screws Item (5) and two Seat

Inserts Item (4) are located inside the Body

Item (1) correctly. It is extremely important not

to install the two Seat Inserts Item (4) too

deep inside the Body. The Seat Inserts must

be flush with the Body surface Item (1). Install

both Needle Screws Item (5) and rotate the

Seat Inserts Item (4) until the flats are

outward towards the sides of the Body as

illustrated in Figure 5.

NOTE: To prevent installation error, once both

Seat Inserts and Needle Screws are installed

inside the Body, install the End Cap Item (3) and

tighten the Socket Head Cap Screws Item (14).

Now pull on both Needle Screws to position the

Seat Inserts before installing the Socket Head

Set Screws Item (30).

3. During re-installation take caution that both

sets of Poppets, top and bottom, are engaged

correctly onto the two Poppet Pins Item (8).

4. It is recommended that small amounts of

petroleum based grease or hydraulic fluid be

used to assist in the reassembly process and

ensure O-ring seals are not damaged.

Maintenance and Service Manual

0.125 PBC 110209

November 4, 2009

1/8" Poppet Block Control

Page 8

5. When installing the End Cap fasteners, Items

(13 and (14) use a fastener lubrication grease

such as Never-Seez

and do not overtorque

Socket Head Cap Screws Items (13) and

(14).

6. Take caution not to pinch or damage the two

manifold O-rings Item (25) while mounting the

completed poppet control assembly on the

actuator footprint. Install and tighten the four

M8 x 50mm Socket Head Cap screws Item

(27) to 52 in-lbs. max.

 Maximum torque for 10-32 x 5/8" Socket

Head Cap Screws Item (13) is 13 in-lbs.

 Maxi

um torque for 1/4-20 x 1" Socket

Head Cap Screws is 25 in-lbs.

SEAL KIT

Item # Quantity Description

23 2 O-ring

10 2 Spring

7 4 Poppets

31 1 O-ring

25 2 O-ring

17 2 O-ring

18 2 Back-up Ring

19 2 O-ring

20 2 O-ring

21 2 O-ring

22 2 O-ring

15 2 Wiper

FIGURE 7

Maintenance and Service Manual

0.125 PBC 110209

November 4, 2009

Page 9

1/8" Poppet Block Control

Notes:

North & South America Europe Middle East & Africa

No 15 Xing Wang Road

Wuqing Development Area

18703 GH Circle Asveldweg 11 2 Monteer Road, Isando Tianjin 301700

PO Box 508 7556 BT Hengelo (O) Kempton Park, 1600 P.R. China

Waller, Texas 77484 The Netherlands South Africa T +86 22 8212 3300

USA T +31 74 256 1010 T +27 11 974 3336 F +86 22 8212 3308

T +1 281 727 5300 F +31 74 291 0938 F +27 11 974 7005

F +1 281 727 5353 Lot 13112, Mukim Labu,

Siemensring 112 PO Box 17033 Kawasan Perindustrian Nilai

2500 Park Avenue West D47877 Willich Jebel Ali Free Zone 71807 Nilai, Negeri Sembilan

Mansfield, Ohio 44906 Germany Dubai, Malaysia

USA T +49 2154 499 660 United Arab Emirates T +60 6 799 2323

T +1 419 529 4311 F +49 2154 499 6313 T +971 4883 5235 F +60 6 799 9942

F +1 419 529 3688 F +971 4883 5312

30/36 Allee du Plateau 471 Mountain Highway

9009 King Palm Drive 93250 Villemomble

Asia Pacific

Bayswater, Victoria 3153

Tampa, Florida 33619 France Australia

USA T +331 48 122610 19, Kian Teck Crecent, T +61 3 9721 0200

T +1 813 630 2255 F +331 48 122619 Singapore 628885 F +61 3 9720 0588

F +1 813 630 9449 T +65 6501 4600

6 Bracken Hill F +65 6268 0028 Delphi B-Wing, 601-602, 6

4112-91A Street South West Industrial Estate Floor, Central Avenue,

Edmonton, Alberta T6E5V2 Peterlee, Co Durham 9/F Gateway Building Hiranandani Business Park,

Canada SR82LS, United Kingdom No. 10 Ya Bao Road Powai Mumbai-400093,

T +1 780 450 3600 T +44 191 518 0020 Chaoyang District Maharashtra India

F +1 789 450 1400 F +44 191 518 0032 Beijing, P.R. China T +91 22 6694 2711

T +86 10 5821 1188 F +91 22 2825 3394

AV. Hollingsworth, 325 3 Furze Court F +86 10 5821 1100

Iporanga 114 Wickham, Hampshire NOF Shinagawa Konan Building

Sorocaba, SP 18087-105 Fareham, Hampshire 1-2-5, Higashi-shinagawa

Brazil PO167SH, United Kingdom Shinagawa-Ku, Tokyo

T +55 15 3238 3788 T +44 132 984 8900 140-0002 Japan

F +55 15 3228 3300 F +44 132 984 8901 T +81 3 5769 6873

F +81 3 5769

6902

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We reserve the right to modify or improve the designs or specifications of the products mentioned in this manual at any time without notice. Emerson Process Management does not assume

responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson Process Management product remains solely with the

purchaser.

Shafer SH-Series Poppet Block Owner's manual

Shafer SH-Series Poppet Block Owner's manual

Shafer SH-Series Poppet Block Owner's manual

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